Grill Cover Buying Guide: How to Choose the Right Cover and Protect Your Investment

 

Grill Cover Buying Guide: How to Choose the Right Cover and Protect Your Investment

A quality grill cover is one of the simplest, most cost-effective ways to protect your outdoor grill investment — but most people buy the wrong one. The wrong cover either traps moisture (causing the exact rust it was supposed to prevent) or breaks down under UV exposure within a single Arizona summer.

Whether you own a built-in or freestanding grill, our carts, parts, and covers collection includes covers designed to fit the premium brands we carry. This guide tells you exactly what to look for before you buy.

How to Choose a Grill Cover: The 4 Things That Actually Matter

1. Polyester vs Vinyl vs Canvas: Which Grill Cover Material Lasts Longest?

Material is the most important decision in your grill cover purchase.

600D polyester is the best all-around choice for most outdoor grills. It's lightweight, UV-resistant, tear-resistant, and breathable enough to prevent moisture buildup underneath. Look specifically for 600D denier rating — anything lower will degrade quickly under direct sun.

Vinyl is fully waterproof but is NOT breathable. In humid conditions or after rain, vinyl traps moisture under the cover, which accelerates rust rather than preventing it. Avoid vinyl unless you live in a very dry climate and remove the cover immediately after rain.

Canvas is the most durable material available, naturally breathable, and excellent for all-weather use. It's heavier and more expensive but outlasts polyester by several years.

Our recommendation for Arizona: 600D polyester with UV inhibitors is the ideal choice. Canvas is worth the upgrade for premium grills over $3,000.

2. Waterproof vs Breathable Grill Covers: Which One Do You Need?

This is one of the most misunderstood distinctions in grill protection. A fully waterproof cover that seals tightly on all sides prevents rain from getting in — but also prevents moisture from escaping. Condensation forms underneath and sits on the grill surface.

A breathable cover allows air circulation while still blocking rain, dust, and UV rays. For most outdoor environments, a breathable cover is the better long-term choice for rust prevention.

3. How to Measure Your Grill for the Right Cover Size

An ill-fitting cover is nearly useless. Here's how to measure correctly:

  1. Width — Measure the widest point of your grill including side shelves

  2. Depth — Measure front to back at the deepest point

  3. Height — Measure from the ground to the tallest point with the lid closed

Add 2–3 inches to each measurement for clearance and easy on/off. A cover that's too small will rip at the seams; one that's too large will collect water pooling on top and blow off in wind.

4. Best Grill Cover for Built-In Grills: Why Fit Matters More Than Price

Built-in grills require a different style of cover than freestanding models. A built-in grill cover only needs to cover the grill head itself — not a full cart — so it must fit precisely to the grill's dimensions. Brand-specific covers from manufacturers like Summerset, Blaze, and Lynx are engineered to fit their grills exactly and are the most reliable choice.

For freestanding grills, universal-size covers work well as long as you measure carefully.

Does a Grill Cover Prevent Rust? Yes — But Only If You Do This

UV Resistant Grill Covers Are Critical in Hot Climates

In Arizona's intense sun, UV degradation is just as damaging to your grill as rain is. UV rays break down stainless steel's protective oxide layer and fade and crack painted surfaces over time. A cover with UV inhibitors in the fabric blocks this process and keeps your grill's finish intact for longer.

Without UV protection, even a well-maintained stainless steel grill will show surface discoloration and pitting within a few years of direct sun exposure.

Should You Cover Your Grill After Every Use?

Yes — but wait until it's completely cool. Covering a hot or warm grill traps heat and steam, which condenses on the grill's interior surfaces and grates. Allow the grill to cool fully (at least 30–45 minutes after cooking) before covering.

This single habit — covering your grill every time after it's fully cooled — is the single biggest factor in extending the lifespan of any outdoor grill, whether it's a pellet smoker from our pellet grills collection or a premium built-in gas grill.

How to Keep Your Grill Cover from Blowing Off in the Wind

Arizona wind is real — and a cover that blows off offers zero protection. Look for covers that include:

  • Velcro straps at the base that wrap under the grill

  • Drawstring hems that cinch underneath the grill cart

  • Weighted corners or snap buckles for heavier-duty covers

Avoid covers that rely only on a friction fit — they will blow off in a moderate wind event.

FAQ: Grill Cover Buying Guide

Does a grill cover prevent rust?
Yes, when used correctly. A breathable, UV-resistant cover that's applied to a fully cooled grill prevents moisture, dust, and UV exposure from degrading your grill's surface. The key is breathability — a non-breathable cover can trap moisture and accelerate rust.

Should you cover your grill after every use?
Yes — every time, after the grill is fully cooled. This is the single most effective maintenance habit for extending grill lifespan.

What material is best for a grill cover?
600D polyester with UV inhibitors is the best all-around choice. Canvas is the most durable upgrade for premium grills. Avoid unlined vinyl in humid or rainy climates.

How do I measure my grill for the right cover size?
Measure width (including side shelves), depth (front to back), and height (lid closed to ground). Add 2–3 inches to each dimension for proper fit.

Can a grill cover cause more rust if it traps moisture?
Yes — this is a real risk with vinyl or non-breathable covers, especially if applied to a warm grill. Always use a breathable cover and let the grill cool completely before covering.

Is it worth buying an expensive grill cover?
Yes, especially if your grill cost over $1,500. A $50–$100 quality cover that lasts 3–5 years is a smart investment compared to the cost of replacing burners, grates, or the grill itself due to preventable weather damage.

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